Additive Manufacturing for Rapid Sand Casting: Mechanical and Microstructural Investigation of Aluminum Alloy Automotive Prototypes

The automotive industry is undergoing a rapid evolution to meet today’s challenges; therefore, continuous innovation and product development are needed. Validation tests on prototypes play a crucial role in moving new components into industrial production. There is also a pressing need for faster prototyping processes. In this context, rapid sand casting (RSC), based on additive manufacturing technology, offers a promising solution for a quick production of sand molds. While this technology is already employed in the industry, the need to deepen the general understanding of its impact on the casting properties is still a relevant item. In this study, different geometries of automotive prototypes made of aluminum EN AC 42100-T6 alloy were experimentally analyzed. Microstructural examinations, tensile tests, and fractography and porosity analyses were conducted. The findings demonstrate the considerable potential of RSC, giving, in general, high mechanical properties. A comparative analysis with prototypes produced through traditional sand casting revealed similar results, with RSC exhibiting superior yield strength and stress at brake. However, both technologies revealed a reduced elongation percentage, as expected. Future efforts will focus on standardizing the RSC process to enhance ductility levels.